Process for preparing zeolite material having an AFX framework structure and zeolite material as prepared

The novel interzeolite conversion process using a diquaternary ammonium cation agent enhances AFX zeolite catalytic activity, achieving superior NOx reduction efficiency in high-temperature applications.

US12649666B2Active Publication Date: 2026-06-09BASF MOBILE EMISSIONS CATALYSTS LLC
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Patent Information

Authority / Receiving Office
US · United States
Patent Type
Patents(United States)
Current Assignee / Owner
BASF MOBILE EMISSIONS CATALYSTS LLC
Filing Date
2021-09-10
Publication Date
2026-06-09

AI Technical Summary

Technical Problem

Existing processes for preparing AFX zeolites are limited to specific starting zeolites and organic structure directing agents, lacking processes that can produce zeolites with improved catalytic activities, particularly for high-temperature NOx selective catalytic reduction.

Method used

A process for preparing AFX framework structure zeolites via interzeolite conversion using a non-FAU framework zeolite and a diquaternary ammonium cation-containing organic structure directing agent, such as N,N,N,N',N'-hexaethyl-1,5-pentanediammonium, to form a zeolite material with enhanced catalytic activity.

Benefits of technology

The resulting zeolite material exhibits significantly higher NOx conversion efficiency, achieving at least 10% to 70% higher SCR efficiency compared to FAU framework structure zeolites, making it effective for high-temperature NOx reduction.

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Patent Text Reader

Abstract

Disclosed herein is a process for preparing a zeolite material having an AFX framework structure including X2O3 and YO2 via interzeolite conversion, the process including (1) providing a mixture including a first zeolite material having a non-FAU framework structure including X2O3 and YO2 and an organic structure directing agent selected from the group consisting of diquaternary ammonium cation containing compounds, and (2) heating the mixture from (1) to form a second zeolite material having an AFX framework structure including X2O3 and YO2, wherein X is a trivalent element and Y is a tetravalent element, and where the organic structure directing agent is not 1,4-bis(1,4-diazabicyclo[2.2.2]octane)butyl dihydroxide when the first material zeolite has a CHA framework structure. Further disclosed herein is the zeolite material having an AFX framework structure as obtainable or obtained from the process, and a method of using the same as a catalytically active material.
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